Method of making and filling cartons



Oct. 12, 1954 w, GE|3LER 2,691,258

METHOD OF MAKING AND FILLING CARTONS Filed Dec. 22, 1949 3 Sheets-Sheet l Q; 37 fravenior 1 1 Q Willa! GealSZr Oct. 12, 1954 w, GElsLER 2,691,258

METHOD OF MAKING AND FILLING CARTONS Filed Dec. 22, 1949 3 Sheets-Sheet 2 v V I I I l 27- I l I i 201 l I l 20 i l {I n @217 F .jf frpz emiar y li o'llz'aim Geais ler fy 51: Q

Oct. 12, 1954 w. GEISLER 2,691,258

METHOD OF MAKING AND FILLING CARTONS Filed Dec. 22, 1949 3 Sheets-s 3 ,l I IIIZII:

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Patented Oct. 12, 1954 METHOD OF MAKING AND FILLING CARTONS William Geisler, New York, N. Y. Application December 22, 1949, Serial No. 134,423

7 Claims.

This invention pertains to the making and filling of shipping containers, particularly containers designed to hold a plurality of independent articles, for example, cans or bottles dis- :posed in orderly rows.

In my copending application for Letters Pat- :ent, Serial No. 106,824, filed July 26, 1949, I have disclosed a novel container designed to be filled through an open side by relative movement in :a substantially horizontal direction of the empty container and a filler unit, the latter comprising the articles to be placed in the container and a spacer grid which holds the articles in the desired rows. The container therein illustrated :is a cardboard carton made from a single piece of sheet material so designed that it may be partially folded, then stitched while moving horirzontally between stitching devices which insert fasteners into the opposite ends of the carton, and then moved to a filling station where the filler unit is introduced through the open side. The carton specifically illustrated in said application has unitary top, rear and bottom walls, and has closure fiaps which collectively constitute the front wall of the closed carton, the carton being filled through its open front, after which the closure flaps are closed and usually sealed.

However, cartons partially formed in accordance with the procedure described in said application may, if desired, be so turned, after the stitching operation is completed, that the initially open closure flaps, when closed, collectively constitute either the top or bottom wall of the filled container instead of its front wall. For some uses, this arrangement is desirable, the filler unit being introduced into the empty container either through said open top or bottom, as circumstances may indicate to be most desirable.

The principal object of the present invention .is to provide a novel method of making and filling containers of the class described. A further object is to provide a novel method of introducing a filler unit into a container while its closure flaps are located at the bottom. A further object is to provide a novel method of making and filling cartons wherein a carton is first made from a unitary piece of sheet material which is partially folded and then stitched while moving horizontally through a stitching zone, and subsequently filled and sealed. A further object is to provide a novel method of introducing a filler unit into a carton while the latter is inverted and for adequately supporting the filler unit during the closing operation. Other and further objects and advantages of the invention will be pointed out in the following more detailed description and by reference to the accompanying drawings where- In:

Fig. 1 is a perspective may be used in the manufacture of a carton in accordance with the present invention;

Fig. 2 is a perspective view showing the same blank partially folded;

Fig. 3 is a vertical section, from front to rear of the partially folded blank, showing the latter mounted on a mandrel to facilitate the stitching of the end-forming members of the blank;

Fig. 4 is a perspective view showing the blank with its ends folded in readiness for the performance of the stitching operation;

Fig. 5 is a perspective view of the embryo carton of Fig. 4 as it appears after the performance of the stitching operation;

Fig. 6 is a transverse section on the line E-6 of Fig. 5, showing the appearance of the end v wall of the container from the inside;

Fig. 7 is a perspective view of the filled carton, with its closure flaps at the top;

Fig. 8 is a perspective view of a filler unit;

Fig. 9 is a fragmentary diagrammatic plan view of apparatus useful in the filling and closing of a carton in accordance with the present invention;

Fig. 10 is a fragmentary diagrammatic side elevation of the apparatus shown in Fig. 9;

Fig. 10 is a fragmentary diagrammatic view showing some of the mechanism which appears at the left-hand portion of Fig. 10, but illustrating a modified form of carton;

Fig. 11 is a fragmentary elevation, similar to Fig. 10, but showing a filler unit as having been inserted in the carton;

Fig. 12 is a fragmentary elevation showing a further step in the closing of the carton;

Fig. 13 is a fragmentary elevation illustrating a still further ste in the closing operation;

Fig. 14 is a perspective view of a carton of modified construction;

Fig. 15 is a plan view ing the carton of Fig. 14;

Fig. 16-is a perspective view illustrating a carton of still further modified construction; and

Fig. 1'7 is a plan view of a blank useful in making the carton of Fig. 16.

The practice of the present invention results in the production of a filled rectangular carton made of sheet material such as cardboard. As here illustrated, a spacer grid, also usually of cardboard, is disposed within the carton, and in view of a blank which of a blank useful in mak- 28 (Fig. 2) are integrallyjoined to the each other, and likewise trating fasteners 33 (Fig. 5)

hesive fastening means may each cell or compartment of the grid there is an article, for example, a bottle. During the earlier stages of forming the carton the filling opening is at one side but prior to filling the carton is turned so that the filling opening is at the bot tom. The carton is made from a unitary blank of the selected sheet material which is scored and slit to facilitate folding and to define the top, bottom and-rear walls, closing flaps and endforming and uniting tabs. One such blank is illustrated by way of example in Fig. 1.

According to one embodiment of the invention the carton, after completion, but before filling and with its filling opening at the front, appears as illustrated in Fig. 5. This carton comprises single thickness unitary walls front and rear 29 and 2! (Fig. 3) integrally joined ;to .a .wall 22 which may constitute the top during the filling operation, but which, after filling, may and usual- 1y does form the one piece,permanently closed bottom of the filled and sealed carton. The front and 'r'earwalls 2b and 2-1 are joined along trans verse edges to the wall 22 at the front and-rear, respectively, of the latter. Main, top closure flaps 23 and 2 are integrally joined-at parallel fold lines to the other transverse edges of the walls 2! and 26, respectively; end-forming tabs 2! and lateral edges of the wall 29; end-forming tabs 25 and 26 (Fig. 2) are integrally joined to the lateral edges of the wall 22; and other end-forming tabs 29 and 30 (Fig. i) are integrally joined to the lateral edges of the wall 2 i. Auxiliary top closure flaps 3i and 32 are also integrally joined along fold lines to the transverse rear edges of the end closure tabs 29 and 30, respectively.

Whenthe carton is first set up (Fig. 4) the end forming tabs 21 and 29 are vertical, and .in overlapping, relation. If the blank is exactly like that ,shownQinFig. 1, the tabs 2'! and 29 will overlap the end forming tabs 28 and .39. l-liowever, if the tabs 21 and 29 and 28 and 33 are of lesser dimensions than shown in Fig. 1, they may not overlap. In anyevent the endforming tabs2! and 29 willoverlap the end forming tab 25, and end forming tabs 28 and 39 willoverlap the end forming tab 25. The tabs .28 and 30 are also vertical, and in overlapping relation. The end forming tabs 25 and 2.6 are also vertical, at right angles to the top wall 22 and overlapped by the endforming tabs 21 and 29, 811 10-22v andB J, respectively, as justnoted. Pene- (herein termed stitches), usually wire staples, unite the overlapped end-forming tabs, the combined tabs .25, 2] and 29 forming one end wall, and the tabs '26, 28 and 39 forming the other end wall of the carton. The amount of overlap of these endforming tabs will vary according to the particular style of carton. While penetrating fasteners are preferably employed, it is contemplated that adbe used within the broader aspects of the invention. After t--e carton has been set up and filled, the main closure'ilaps 23 and 24 are folded in to lie parallel to the top wall 22; the auxiliary end closure flaps 3| and 32 likewise being folded to lie parallel to the wall 22, and the several closure flaps are united by adhesive or other fastening means, thus completing the filled container.

Assuming that blanks B (Fig. l) properly dimensioned, scored and slit have been prepared, a supply of such blanks may be stacked in a suitable magazine, and from this magazine the blanks are drawn one at a time in succession,

horizontally and spaced apart by the while :the end closure tabs and the "end closure turned to lie in vertical planes and so that they overlap the end closure "oration-is illustrated in rooms. The mandrel is intermittent or step-by-step.

. example wire staples,

either by hand or mechanically. Initially the blank is fiat and horizontal, being supported in this horizontal position by any suitable means. for example, by an elongate table top or bench, or by the upper run of a conveyor. The blank is first moved to a station where it remains for a sufficient interval of time to permit the first folding operation whereby the wall 22 is first disposed vertically v andthe walls 28 and 2i are disposed width of the wall 22. The result of this folding operation is illustrated in Fig. 2. At this time the main closure flaps 23 and 2d are horizontal and disposed in the same planes as the walls 2! and 20, respectively. At this time the tabs 25 and 26 are vertical, lying in the same plane as the wall 22, 21, 23, 29 and 36, and the auxiliary flaps 3i and 32 are horizontal. This partially folded blank or embryo carton is now moved horizontally to an end-folding station into the embryo carton,

The end closure tabs 25 and 26 are now turned in so-as to stand at right angles to the wall 22 tabs 21, 29 and '23, 30 are tabs 25 and"26. This folding operation may be carried outmanually or automatically. The result of this foldingop- Figmi, the embryo carton now being set up and its ends being closed in readiness to be stitched. The mandrel ki l has an external contour and dimensionslike those of the interior of thecarton to be made. Each side wall of the mandrel has a hard wear-resistant anvil, if staples are used as the fastening eleis now further advanced and by pressure against the wall 22 moves the embryo carton into a stitching zone. The advance of the carton through this stitching zone In passing through this zone, penetrating fasteners 33, for are inserted at each step of the intermittent movement of the carton so as to unite the end closure tabs 21 and 29 tothe end closure tab 25 and the end closure tabs 28 and 30 to the endclosure tab 26; These staples are clenched against the wear-resistant surfaces of the. mandrel 54.

As suggested, these fasteners are .preferably work-penetrating elements such as staples, rivets ,orother type of metallic fastener; however, they .may be sewing stitches and they may be introduced by hand .or machine.

.ing mechanism of any appropriate kind is arranged at each side .of the path of movement of .the carton as thelatter is advanced through the stitching .zone, each fastener inserting mechanism being so designed as to insert a fastener into the overlapping end-forming tabs of the carton at one end respectively of the latter. The result of this fastener inserting operation is indicated in Fig. 5, the carton being shown as having four staples in each side. However, a greater or lesser number of staples may be inserted .if desired. At the completion of this operation, the closure flaps 23 and 24 are still in the horizontal position. After the last staples have been inserted, the embryo carton is advanced in any desired way to the filling or loading station. However, on its way to the filling or loading station, it is so turned, either mechanically or by hand, that the wall 22 is uppermost, the carton being inverted and having its filling opening at the bottom during the filling operation.

At the loading station (Fig. rear closure flap 23 remains in the vertical plane of the wall 2|, the auxiliary closure fiaps 3! and 32 are turned outwardly (Fig. 9) to lie in a horizontal plane, and the front main closure flap 24 is also turned outwardly to lie in the same horizontal plane, thus leaving the bottom opening wide open. Any appropriate means may be employed for holding the carton in this inverted position with the flaps 24, 3! and 32 horizontal. -At the filling station a load or filler unit is introduced into the carton. by way of example, but without limiting intent,

the main,

sheet material, for example, cardboard, arranged to provide a plurality of pockets or cells, each of such dimension as to be capable of receiving 66, for example, a bottle,

carton.

The filler unit 63 is prepared in readiness for introduction into the empty carton in any desired way, for example, by hand or mechanically. The articles 66 may be supplied by conveyor means and are delivered-to provide the desired number of rows of articles to form a filler block tinues to move in the same direction, the closure flap 24 is swung through an arc of 180, the supports S, hereafter referred to, being withdrawn and 32, and each of these flaps is then turned through an angle of 180 so as to underlie the closed flaps 23 and 24. The carton 23 and 24 until the glue has set. The filled and closed carton may now be stored or shipped; usually it will be inverted so that the wall 22 becomes the bottom wall before it is stored or shipped.

By way of example, apparatus useful in filling and closing the container is diagrammatically illustrated in Figs. 9 to 12, inclusive. As shown in Fig. 10, bottles 66 are being delivered by a conveyor 6! to an elevator 10. When sufficient bottles to fill the carton have been deposited upon the elevator, the further advance of bottles is stopped in any suitable way, for example, by means of a rigid baifle plate or guard G depending from the elevator and which, as the elevator begins to rise, blocks the path of advance of the bottles. As illustrated in Fig. 10, horizontal grid-supporting elements W may be provided, these supporting elements being placed directly above the elevator and on these supporting elements the grid is placed so that one of the bottles enters each grid cell as the elevator rises. Assuming that the empty carton has been inverted over the grid and is thus directly above the elevator, as shown in Fig. 10, the elevator is caused to rise, thus lifting the block of bottles until one bottle has been entered into each cell of the grid, as shown in Fig. 11. The elevator dwells in this position while a pusher 1| engages the left-hand orfront wall of the carton and pushes the latter horizontally from off the elevator. To the right of the position of the empty carton (as shown in Fig. 10) there are arranged two thin, horizontal blade-like supports S and S (Fig. 9) whose upper surfaces are disposed in a horizontal plane preferably slightly below that of the upper surface of the elevator when the latter is in its. highest position. These blade-like supports S and S are capable of movement in opposite directions transversely of the direction of movement of the pusher H. As the pusher l'l begins its movement to the right, these supports S and S occupy their proximate, relative positions shown in Fig. 9, and as the filled carton starts to advance horizontally, its right-hand portion begins to ride up onto the supports S and S', the left-hand edges of which engage the downwardly directed closure flap 23 and cause the latter to swing upwardly as shown in Fig. 11, so that eventually it becomes horizontal, the carton.

members S and S, descends.

As here shown, by wayof example, the pusher carries a transverse, rotatable shaft 12 (Fig. 9) provided at its opposite ends with segmental pinions 73 which engage fixed horizontal bars Q provided, at the areas H, with rack teeth so that, as the pusher advances to the right, the pinions are brought and the shaft 12 is A flapturning arm 15 is secured to the central part of the shaft 12. This arm 15 is horizontal and overlies the front closure flap 24 when the parts occupy the position shown in Fig. 10, but asthe pusher advances to the right, this arm '15 begins to turn, and, by contact with the flap 24, swings the latter through an are such that the free margin of the flap 24 underlies the thin, bladelike supports S T and the supports S and S begin to move away from each other, thus providing space between their proximate edges for the main closure flap The table .T' has a downwardly inclined finger F which contacts the free edge of the flap 24 as the carton is further moved to the right, thus completing the upswing or the flap 24 to horizontal position where it underlies the filler unit within the carton. As soon as the edge of the flap 24 contacts the finger F, the pusher 1| returns to its initial position and further motion of the carton is occasioned by bars Z carried by endless chains Y or equivalent means. During advance of the carton along the table T, the auxiliary closure flaps 3| and 32 pass over the surfaces of glue coated rolls R. which apply adhesive to the under surfaces of the flaps. The auxiliary fiaps 3| and 32 then engage fixed turning scrolls C which, as the carton continues to advance toward the right, turn the flaps through arcs of 180 so that they underlie the closed main closure flaps 23 and 24. The bars Z move the carton along until it slides off of the table T and onto a conveyor this final motion, the carton may be subjected to pressure, for example, by a pressure roll (not shown) so as to hold the auxiliary fiaps 3| and 32 in contact with the flaps 23 and 24 until the adhesive has set. The filled carton is then usually turned so that the closure flaps are at the top, as shown in Fig. '1.

In Fig. Hi a carton K, similar to that illustrated in the aforementioned copending application Serial No. 106,824, is shown in inverted position to receive a filler unit which is moved upwardly into the carton. The carton is disposed with the flap 23 in substantially vertical position and with the flap 24 bent outwardly and horizontal. In this instance the fiap 23 has integral sealing tabs 3| and 32 which are bent to lie in parallel planes at right angles to the main portion of the flap 23*. As the flap 23 is swung upwardly into closing position during the movement of the carton, through the several positions illustrated in Figs. 11, 12 and 13, the sealing tabs 3F and 32 enter the carton between the side walls of the latter and the filler unit. Adhesive may be applied to these sealing tabs 31 and 32 before the part 23 is folded up, so as to unite the sealing tabs 3| and 32 to the carton wall.

In Fig. 14 a carton of slightly modified form is illustrated, capable of being made, filled and closed in substantial accordance with the method i hereinbefore described. This carton is made from the blank shown in Fig. 15 wherein parts corresponding to those of the blank of Fig. 1 are similarly designated.

The carton shown in Fig. 14 is wider in proportion to its height than the carton formed from the blank of Fig. 1 so that, when set up, the end closure tabs 21 and 29 do not overlap but have their vertical edges in abutting relation, the same being true of the end closure tabs 28 and 30. In this blank, the end closure tabs 29 and 30 have the auxiliary closure fiaps 3| and 32 integrally joined to their transverse edges, as in Fig. l, but in this blank the tabs 21 and 28 likewise have auxiliary closure flaps 3| and 32*. During the stitching operation staples 33 (Fig. 14) are driven through the end closure tabs 21 and 29 into the end closure tab 25 at one end of the carton, and at the other end staples are driven through the end closure tabs 28 and 3|! into the end closure tab 26, as previously described, but the stitching operation is continued so as to unite the proximate edges of the auxiliary closure flaps 3| and 3| and 32 and 32 respectively. The united auxiliary closure flaps K. During and 32 now constitute the After the stitching operation, with the wall 22 of the carton disposed vertically, the carton is turned as above described so that its open side is now at the bottom and the filling and closing operation is carried out as above described. While it is preierred to unite the adjacent edges of the auxiliary closure flaps 32 and 32 and 3| and 3| as above suggested, this is not essential and these fiaps at each end may be left free from each other.

In Fig. 16 a further modification is illustrated wherein the carton is quite shallow as compared with its horizontal dimensions. This carton may be made from a blank such as shown in Fig. 1'1 and filled and closed in substantial accordance with the method above described. In Fig. 17 parts of the blank corresponding to those of the blank of Fig. 15 are similarly designated. The blank is substantially like that of Fig. 15 except for relative diiierence in the size of parts and that the auxiliary closure flaps 3|, 32, 3P and 32 are omitted and tabs 25 and 28 have auxiliary closure fiaps 25 and 26 at their lateral edges.

In setting up this blank, the wall 22 is vertically disposed, as above described, the walls 20 and 2| being horizontal, the longer dimensions of the tabs 25 and 26 being vertical. During the stitching operation the auxiliary closure flaps 25 and 26 lie in the same planes as the tabs 25 and 25 respectively. Because the tabs 21, 28, 29 and 33 are quite narrow as compared with the lengths of the tabs 25 and 26, it is necessary to employ two rows of stitches 33 in forming the end walls of the carton, one row of stitches uniting the tabs 25 and 29 and another row uniting the tabs 25 and 21 at one end of the carton, while at the other end one row of stitches unites the tabs 28 and 26 and the other unites the tabs 33 and 26. If the fasteners are inserted by machine it may be necessary to employ two fastener-inserting devices, one above the other at each side of the path of travel of the carton through the stitching zone. Alternatively the carton may be fed through the stitching zone while inserting one row of fasteners at each end, and then retracted, turned upside down and again fed through the stitching zone to insert the other row of fasteners at each end.

After stitching, the carton is inverted, the closing flaps and end-forming tabs are arranged as above described in respect to the carton of Fig. l, the filler unit is inserted by upward movement through the bottom opening of the carton, and the flaps and tabs are closed and secured.

While for convenience reference has herein been made to front, rear and end wal these terms are used merely for clarity in description and without limiting intent. Likewise while in describing apparatus for use in filling and closing the carton certain specific descriptive terms have been used, it is to be understood that these are merely suggestive of any equivalent parts, elements or devices appropriate for the performance of the desired function, and while one desirable type of mechanism has been shown for use in performing the filling and closing operations, it is to be understood that this apparatus is merely by way of example and that other apparatus may be employed, or that the several operations may be carried out by hand.

While certain desirable embodiments of the invention have been herein specifically illustrated by way of example, it is to be understood that the invention is broadly inclusive of any and all 3| and 3| and 32 end closure flaps. which is performed modifications falling within the scope of'the appended claims. a

I claim:

tom but open at its top'and provided at its top ,with main closure flaps hinged to its front and rear walls, respectively and auxiliary closure depending position, turning the front main closure flap and the auxiliary closure flaps outwardly so as to leave the top of the carton comthe main rear flap upwardly so as to underlie the filler unit, then turning the main front closubstantially rigid one-piece container of sheet material having front, rear, bottom and end walls, main top closure flaps integrally joined to the top edges of the front and rear walls respectively, and auxiliary top closure flaps integrally joined to the top edges of the respeccontainer and so ing the main closure flap WhlCh 1s connected to the rear wall in a substantially vertical plane, turning the main closure flap which is connected to the front wall and also the auxiliary closure flaps outwardly to lie in a substantially horisubstantially rigid material having front,

zontal plane, thereby leaving the top of the container completely open,

uniting the closed flaps.-

, 4.,That method of making a filled shipping container which comprises as stepsproviding a one-piece container of sheet rear, bottom and end walls,

integrally joined to ing the main closure flap attached to the rear wall to a horizontal position Where it underlies the filler unit, then swinging the main closure flap which is attached to the front Wall until it underlies the filler unit, continuing the advance leaving the top of the container completely open, providing a filler material having unit, and while continuing to advance the container along the same rectilinear path, applying adhesive to the under surfaces of the horizontally disposed auxiliary closure flaps, swinging said auxiliary closure flaps to underlie the main closure flaps and applying pressure to the container to unite the adhesively coated auxiliary closure flaps to the main closure flaps.

6. That method of making a filled shipping container which comprises as steps providing a substantially rigid, rectangular one-piece container of sheet material having front, rear, bottom and end walls, main top closure flaps integrally joined and hinged to the top edges of the front and rear walls respectively, and-auxiliary top closure flaps integrally joined to the=top edges of the respective end Walls, inverting the container and so disposing it that its bottom wall is uppermost and horizontal, and with its-closure flaps so disposed as to leave the top of the container completely open, moving a filler unit 'upward and into the container, and while uninterruptedly advancing the container along a rectilinear path substantially perpendicular to the hinge joint between the rear wall and the closure flap which is attached thereto, moving the-main closure flaps to underlie the filler unit, turning the auxiliary'closurefiaps to-closed position and uniting the main and auxiliary closure flaps.

7. That method of making a filled shipping container which comprises as steps providing a substantially rigid one-piece container of sheet front, rear, 'bottom and "end walls, main top closure flaps integrally joined and hinged to the top edges of the front and rear walls respectively, and auxiliary top closure flaps integrally joined to the top edges ofthe respective end walls, inverting the container and so disposing it that its bottom wall is uppermost and substantially horizontal, and with its closure flaps so disposed as to leave the top of the container completely open, elevating a filler unit to introduce the filler unit into the container, advancing the filler and container uninterruptedly along a horizontal rectilinear path perpendicular to the hinge line at which the rear Wall and its closure flap are united while successively swinging the two main closure flaps upwardly to underlie the filler unit, turning the auxiliary flaps to closed position and uniting the main and auxiliary flaps.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 156,333 Clark Oct. 27, 1874 639,269 McMillin Dec. 19, 1899 736,237 Doble Aug. 11, 1903 807,140 Sunderman Dec. 12, 1905 1,430,148 Bliss Sept. 26, 1922 1,680,932 Bliss Aug. 14, 1928 1,315,571 Kimball et al. July 21, 1931 1,888,818 Daller Nov. 22, 1932 2,047,272 Kimball et al. July 14, 1936 2,145,632 Bergstein Jan. 31, 1939 2,252,106 Waters Aug. 12, 1941 2,276,129 Wesselman Mar. 10, 1942 2,394,936 Palmer Feb. 12, .1946 

